High-strength alloy based on aluminium and a product made of said alloy

ABSTRACT

The present invention relates to high-strength aluminium-based alloy of Al—Zn—Mg—Cu system and the article made thereof. Said alloy can be used as a structural material in aircraft—and rocket engineering, and for fabricating the articles for transportation—and instrument engineering.  
     The advantage of the suggested alloy is its high strength and the required level of service properties combined with sufficient technological effectiveness necessary for fabricating various wrought semiproducts, mainly of large sizes. Said alloy has the following composition (in wt %):  
     zinc 7.6-8.6  
     magnesium 1.6-2.3  
     copper 1.4-1.95  
     zirconium 0.08-0.20  
     manganese 0.01-0.1  
     iron 0.02-0.15  
     silicon 0.01-0.1  
     chrome 0.01-0.05  
     nickel 0.0001-0.03  
     beryllium 0.0001-0.005  
     bismuth 0.00005-0.0005  
     hydrogen 0.8×10 −5 -2.7×10 −5  and  
     at least one element from the group including  
     titanium 0.005-0.06  
     boron 0.001-0.01  
     aluminium-balance.  
     The following conditions should be observed:  
     the sum of zinc, magnesium, copper should not exceed 12.5%;  
     the sum of zirconium, manganese, chrome and nickel should not exceed 0.35%;  
     the ratio Fe:Si should not be less than 1.2.  
     Said alloy is recommended for use as a structural material for main members of aircraft airframe (upper skin, stringers of the wing, loaded beams, etc.

FIELD OF THE INVENTION

[0001] The present invention relates to non-ferrous metallurgy, and in particular it relates to high strength alloys of Al—Zn—Mg—Cu system used as a structural material for main parts in aircraft (upper skins and stringers of the wing, loaded beams, etc), in rocket-, transportation and instrument engineering.

BACKGROUND OF THE INVENTION

[0002] Well-known are high strength aluminium-based alloys of Al—Zn—Mg—Cu system additionally doped with a minor amount of zirconium.

[0003] The Russian alloy 1973 has the following composition (in weight %):

[0004] zinc 5.5-6.5

[0005] magnesium 2.0-2.6

[0006] copper 1.4-2.0

[0007] zirconium 0.08-0.16

[0008] titanium 0.02-0.07

[0009] manganese ≦0.10

[0010] chrome ≦0.05

[0011] iron ≦0.15

[0012] silicon ≦0.10

[0013] aluminium-balance [1]

[0014] The American alloy 7050 comprises (wt %):

[0015] zinc 5.7-6.7

[0016] magnesium 1.9-2.6

[0017] copper 2.0-2.6

[0018] zirconium 0.08-0.15

[0019] titanium ≦0.06

[0020] manganese ≦0.10

[0021] chrome ≦0.04

[0022] iron ≦0.15

[0023] silicon ≦0.12

[0024] aluminium-balance [2]

[0025] Also is patented the American alloy comprising (wt %):

[0026] zinc 5.9-6.9

[0027] magnesium 2.0-2.7

[0028] copper 1.9-2.5

[0029] zirconium 0.08-0.15

[0030] titanium ≦0.06

[0031] chrome ≦0.04

[0032] iron ≦0.15

[0033] silicon≦0.12

[0034] aluminium-balance [3]

[0035] The common disadvantage of all said alloys is the unsatisfactory level of static strength and specific characteristics which doesn't allow to improve service properties, to increase the weight efficiency of the articles aiming to raise carrying capacity, to save fuel, to increase flight distance range, etc.

[0036] The American alloy is suggested comprising (wt %):

[0037] zinc 7.6-8.4

[0038] magnesium 1.8-2.2

[0039] copper 2.1-2.6

[0040] zirconium 0.03-0.30

[0041] manganese 0.1-0.35

[0042] iron 0.03-0.1

[0043] silicon 0.03-0.1

[0044] and at least one element from the group including

[0045] hafnium 0.03-0.4

[0046] vanadium 0.05-0.15

[0047] aluminium-balance [4]

[0048] Said alloy has the following disadvantages:

[0049] high and superhigh strength is mainly achieved by heavy alloying with main elements—zinc, magnesium, copper (their maximum sum >13.0%), but the increased amount of copper leads to the reduction of ductility, crack—and fatigue resistance;

[0050] the additional alloying with expensive elements (hafnium, vanadium) is used, and that leads to the increase in cost of semi-finished products and finished articles, especially when there is a large-scale production and the products are of large sizes;

[0051] the alloy has the unsatisfactory ductility in as-cast condition (and therefore has the tendency to appearing of cracks in ingots especially large-sized ingots which are cast from such alloys with difficulty) and under the deformation of semiproducts;

[0052] the alloy's composition doesn't provide the optimum conditions of the microstructure formation and service characteristics of such members as skins and stringers of the wing which are needed for modem and future aircraft.

DESCRIPTION OF THE INVENTION

[0053] The object of the present invention is to provide an alloy having high strength and the desired level of service characteristics necessary for main loaded members of airframe in aircraft, rockets and other articles, in combination with satisfactory technological effectiveness for fabrication of various wrought semiproducts especially of large sizes.

[0054] According to the invention, there is provided the high strength aluminium-based alloy of Al—Zn—Mg—Cu system comprising (in wt %):

[0055] zinc 7.6-8.6

[0056] magnesium 1.6-2.3

[0057] copper 1.4-1.95

[0058] zirconium 0.08-0.20

[0059] manganese 0.01 -0.1

[0060] iron 0.02-0.15

[0061] silicon 0.01-0.1

[0062] chrome 0.01-0.05

[0063] nickel 0.0001-0.03

[0064] beryllium 0.0001-0.005

[0065] bismuth 0.00005-0.0005

[0066] hydrogen 0.8×10⁻⁵-2.7×10⁻⁵

[0067] and at least one element from the group consisting of

[0068] titanium 0.005-0.06

[0069] boron 0.001-0.01

[0070] aluminium-balance,

[0071] and the article made thereof

[0072] The sum of the main alloying elements (zinc, magnesium, copper) should not exceed 12.5%. The sum of the transition elements (Zr, Mn, Cr, Ni) should not exceed 0.35%. The ratio Fe: Si should be not less than 1.2.

[0073] Together with the main element-antirecrystallizer Zr, the introduction of Cr, Ni into the suggested alloy's composition, and the reduction of Mn amount (the claimed range of the total sum be not more than 0.35%) ensures the formation and stabilization of unrecrystallized structure, nucleation of hardening phases and hence, the increase in strength, and also raises the stress corrosion cracking resistance and exfoliation corrosion resistance.

[0074] The microalloying of the alloy with grain refining titanium additive of nucleation sites effect and/or boron additive causes the heterogenious solidification of the alloy and hence, grain refining and its uniformity, secondary phases' dispersion in ingots. Bismuth also has a grain refining effect and it increases the fluidity. All of said improve the ductility of ingots and semiproducts, and extend the possibility to enlarge their dimensions and to increase the quality.

[0075] Hydrogen being present in microamounts, promotes the formation of fine-grain structure, uniform distribution of inevitable non-metallic inclusions through the volume of ingots and semiproducts, and the increase in their ductility. The inclusion of a technological additive of beryllium reduces the oxidability and improves the fluidity in casting process, additionally improving the quality of ingots and semiproducts.

[0076] It is quite necessary to exceed the amount of iron over the amount of silicon (by more than 1,2 times) while strictly limiting these amounts (especially of silicon), for the purpose of improving the casting properties of Zn-containing alloys in order to make possible the fabrication of large-sized ingots and semiproducts.

[0077] The reduction of copper amount (to 1.95 wt %) and of total degree of alloying with main elements (Zn, Mg, Cu) to 12.5 wt % suppresses the possibility of formation of coarse excessive insoluble intermetallics like S(Al₂CuMg) phase etc, and limits their unfavourable influence upon ductility, crack resistance and fatigue, while not reducing the corrosion resistance.

[0078] Embodiments of the present invention will now be described by way of examples.

EXAMPLES

[0079] In experimental trials the ingots were cast, and Table 1 shows the compositions of the alloys. The alloys 1-6 are the alloys according to the present invention, and alloy 7 is the example of the invention of U.S. Pat. No. 5,221,337. The ingots had the diameter of 110 mm. They were cast by semi-continuous method with water cooling. Casting was performed in electric furnace. After homogenization at 460° C. for 24 hours, the values of ingots' ductility were estimated, which values characterize the ingots' ability to hot deformation at typical temperature of 400° C. in semiproducts' fabrication process. Two methods were used: upset forging of the samples Ø 15×20 mm with the determination of ultimate deformation ε; tensile testing of round samples (gauge length diameter d_(o)=4 mm) with the determination of relative elongation δ (upon gauge length l_(o)=5d_(o)) and relative reduction of area ψ.

[0080] The average grain size d_(aver) in the ingots were determined by the method of quantitative metallography of polarized microsections.

[0081] After homogenization some of the ingots were extruded at 390-410° C. into bars of 12×75 mm cross-section. The billets of extruded bars were solution treated from temperature of 467° C. (for 50 minutes) and quenched in cold water (20-25° C.). In the range of 4 hours after quenching the bars were subjected to artificial ageing of T₁ according to the scheme: 140° C., 16 hours.

[0082] The mechanical and corrosion properties were determined on samples cut from bars.

[0083] The mechanical properties upon tensile testing (tensile strength, elongation, reduction in area) were determined on round specimen with gauge length diameter d_(o)=5 mm. Crack resistance was estimated by impact toughness of a specimen with V-shaped notch and a fatigue crack according to GOST 9454.

[0084] Low cycle fatigue resistance (LCF) was estimated by time to fracture of the round longitudinal specimen with circular notch (K_(t)=2.2) under high stress (σ_(max)=0.7 UTS of notched specimen) and frequency f=0.17 Hz.

[0085] The corrosion properties were estimated by:

[0086] stress corrosion cracking resistance (SCC) by time to fracture of long transverse specimens under stress σ=0.75 YTS and under other conditions according to GOST 9.019;

[0087] exfoliation corrosion resistance (EXCO) of flat longitudinal specimens on 10-ball scale according to GOST 9.904.

[0088] Table 2 illustrates the combination of mechanical and corrosion properties of extruded bars made of suggested alloy and of the prior art alloy. Table 3 shows the values of technological ductility of the ingots made from said alloys.

[0089] As one can evidently see from the shown results, the composition of the claimed alloy allowed to increase noticeably the values of ductility and crack resistance (by ≈15-20%) while providing the high level of strength properties, preserving the stress corrosion resistance and improving to some extent the exfoliation corrosion—and fatigue resistance. Said composition provides the improvement in structure and technological ductility of ingots, making the casting process and the forming of the semiproducts easy.

[0090] Thus, the claimed alloy provides the increase in weight effectiveness, reliability and service life of the articles. The alloy is recommended for fabrication of rolled (sheets, plates), extruded (profiles, panels, etc) semiproducts including long-sized products from large ingots, and also forged semiproducts (die forgings and hand forgings).

[0091] Said alloy may be used as structural material for fabricating the main members of airframe in aircraft, especially in compressed zones (upper skins and stringers of the wing, loaded beams, etc), rockets and other articles. TABLE 1 Chemical compositions of the alloys Alloy Zn Mg Cu Zr Mn Cr Ni Ti B Be Bi Fe Si H · 10⁻⁵ 1 8.3 2.3 1.9 0.13 0.1 0.04 0.005 0.05 — 0.005 0.0002 0.1 0.04 0.8 2 8.6 2.1 1.4 0.14 0.07 0.04 0.008 — 0.008 0.002 0.0005 0.15 0.05 1.5 3 7.6 2.0 1.95 0.17 0.1 0.05 0.03 0.06 0.001  0.0001 0.0001 0.14 0.06 2.7 4 8.0 1.9 1.8 0.13 0.06 0.03 0.0001  0.005 0.01  0.003  0.00008 0.13 0.04 2.0 5 8.1 2.0 1.9 0.08 0.07 0.05 0.02 0.05 — 0.002 0.0003 0.12 0.1 1.8 6 7.9 1.6 1.7 0.20 0.01 0.01 0.01 0.04 0.003 0.001  0.00005 0.02 0.01 1.4 7 8.4 2.2 2.5 0.12 0.1 0.02 Hf 0.15 V — — — — 0.1 0.06 —

[0092] TABLE 2 Mechanical and corrosion properties of the semiproducts LCF, SCC, % Impact cycle time to MPa Reduction toughness number to fracture, EXCO, Alloy UTS YTS E1 of area J/cm² fracture hour point 1 690 670 10.0 16.5 4.0 1100 174 6 2 685 665 10.5 18 4.3 1040 172 6 3 675 655 11.5 20 4.6 1200 180 6 4 685 665 11.0 20 4.5 1150 173 7 5 680 660 10.5 19 4.4 1040 174 7 6 685 665 10.0 17 4.2 1100 175 6 7 690 670 9.0 15 3.8 1050 173 7

[0093] TABLE 3 Technological ductility of ingots at 400° C. Tension Average grain Upset forging E1, δ Reduction, ψ Alloy Size, d_(aver), μm ε, % % 1 260 49 74 92 2 230 55 76 93 3 210 60 82 95 4 320 48 74 92 5 250 55 75 93 6 270 50 74 93 7 380 43 71 90

References

[0094] 1. New non-ferrous alloys. Moscow, MDNTP, 1990, p. 33.

[0095] 2. Aluminium Standards and Data. The Aluminum Association, Washington, 1998, p. 6-6.

[0096] 3. U.S. Pat. No. 4,305,763. US Class 148/12.7A, Int. Cl. C22F 1/04, publ. 15.12.1981.

[0097] 4. U.S. Pat. No. 5,221,337, US Class 148/417, Int. Cl. C22C 21/06, publ. 22.06.1993. 

1. High strength aluminium-based alloy comprising (wt %): zinc 7.6-8.6 magnesium 1.6-2.3 copper 1.4-1.95 zirconium 0.08-0.20 manganese 0.01 -0.1 iron 0.02-0.15 silicon 0.01-0.1 chrome 0.01-0.05 nickel 0.0001-0.03 beryllium 0.0001-0.005 bismuth 0.00005-0.0005 hydrogen 0.8×10⁻⁵-2.7×10⁻⁵ and at least one element from the group including titanium 0.005-0.06 boron 0.001-0.01 aluminium-balance.
 2. High strength aluminium-based alloy of claim 1, characterized in that the sum of zinc, magnesium and copper should not exceed 12.5%.
 3. High strength aluminium-based alloy of any of claims 1-2, characterized in that the sum of zirconium, manganese, chrome and nickel should not exceed 0.35%.
 4. High strength aluminium-based alloy of any of claims 1-3, characterized in that the ratio Fe:Si should be not less than 1.2.
 5. The article made of high strength aluminium-based alloy, characterized in that said article is made of the alloy comprising (wt %): zinc 7.6-8.6 magnesium 1.6-2.3 copper 1.4-1.95 zirconium 0.08-0.20 manganese
 0. 01 -0.1 iron 0.02-0.15 silicon 0.01-0.1 chrome 0.01-0.05 nickel 0.0001-0.03 beryllium 0.0001-0.005 bismuth 0.00005-0.0005 hydrogen 0.8×10⁻⁵×10⁻⁵ and at least one element from the group including titanium 0.005-0.06 boron 0.001-0.01 aluminium-balance. 